Epoxy resin bonded flexible graphite laminate and method

Abstract

A flexible graphite laminate of flexible graphite and a core material bonded through an intermediate coating of an epoxy resin composite comprising an epoxy resin having a glass transition temperature after cure of below 120 DEG C. and particles of a thermoplastic agent dispersed in the epoxy resin and having a crystalline or partially crystalline structure and a melting temperature of between 120 DEG C. and 200 DEG C.

What we claim is: 
     
       1. A flexible graphite laminate of flexible graphite and a core material composed of metal, fiberglass or carbon with the flexible graphite bonded to said core material through an intermediate coating of an epoxy resin composite comprising an epoxy resin having a glass transition temperature after cure of below 120° C. and particles of a thermoplastic agent dispersed in the epoxy resin and having a crystalline or partially crystalline structure and a melting temperature in the range of 120° C. and 200° C. with the laminate formed upon contact between said flexible graphite, said core material and a cured coating of said epoxy composite upon reheating at a temperature equal to or above the melting temperature of said thermoplastic agent. 
     
     
       2. A flexible graphite laminate as defined in claim 1 wherein the concentration of said thermoplastic agent in said epoxy resin is between 5 to 30 percent by weight. 
     
     
       3. A flexible graphite laminate as defined in claim 2 wherein the concentration of said thermoplastic agent in said epoxy resin is between 8 and 15 percent by weight. 
     
     
       4. A flexible graphite laminate as defined in claim 2 wherein said thermoplastic agent is selected from the group consisting of: polyethylene; polypropylene; poly-1-butene; poly-1-pentene; poly-4-phenyl-1-butene; polyoxymethylene and Nylon 8,γ. 
     
     
       5. A flexible graphite laminate as defined in claim 4 wherein said thermoplastic agent is selected from the group consisting of: polyethylene; polypropylene; poly-1-butene; poly-1-pentene; poly-4-phenyl-1-butene; polyoxymethylene and Nylon 8γ.